Introduction: Olivier Casting Unit 2 Design 10A

This is casting plaster 2020.

Step 1: Research Your Design Idea

Using your computer research or develop the Geometrical Net Idea that you feel is appropriate. In my case, I was inspired by the image attached. I excluded the top hexagon, making it so I would use, one hexagon and six side strips. Use this image as a referencing point during the drawing and designing process.

Step 2: Start Drawing and Cutting Out the Pieces

Next, draw out one hexagon using a compass and a set square and six (5 by 8cm) strips as seen in the image above on a piece of paper and then, using the paper and scissors, cut out the pieces on High Impact Polystyrene (HIP) and make a smaller (3 by 8cm) core using HIP

Step 3: Create the Model

As seen in the image above, tape the strips firmly to the hexagon in the middle leaving no space between the strip and the hexagon for both the core and the mould.

Step 4: Tape the HIP Together

Using tape, tape the HIP together firmly to avoid spillage, as seen above (the example is made of card but the shape should be similar with HIP). Once you've finished taping the sides together you have successfully made the core and mould.

Step 5: Prepare to Cast

In order to make the casting solution you will need:

1 bucket

2 cups

1 stirring rod

Follow the ratio of 2 cups of water and 3 cups of powder

Add two cups of water and then add 3 cups of powder and always keep stirring

Once the solution is thick enough carefully pour the mixture into the prototype and then after 5 seconds add the core in the desired location and firmly push down.

Step 6: Secure the Core

Using tape as seen in the photos above, secure the core to the sides to ensure the core will stay in place and the final product will set neatly.

Step 7: Cut Open the Mould

After 24 hours of letting the mould set:

Carefully cut off the High impact Polystyrene using a cutter.

IMPORTANT: Very little pressure needs to be put on the cutter as it easily cuts through the HIP and if you use too much pressure you risk cutting the mould itself.

Step 8: Carefully Take Out the Core

Carefully take the core out by hand and be careful not to use too much pressure. After taking it out the product should look like the image above.

Step 9: Final Product

Feel free to sand the product or add anything but you have now made your final product.